Composite camouflage construction and method for manufacturing composite camouflage construction

ABSTRACT

An improved camouflaged product and method of making such a product is disclosed. A multi-layered camouflage construction may comprise a first textile substrate and a second textile substrate secured to each other along parallel lines of stitching. The second textile substrate may be cut to form lobes oriented transversely to the lines of stitching to simulate the appearance of natural objects in the terrain, such as leaves or foliage. Thread which is capable of shrinking is used to attach textile substrates to each other, and then the thread is heated to shrink the thread into the stitch, forming a hardened seam with gathering and bunching of one or more substrates along the seam. Gathering of substrate along a seam contributes to the three-dimensional visual effect of the camouflage construction.

BACKGROUND OF THE INVENTION

[0001] Camouflaged materials are used to conceal objects, personnel, andequipment in natural terrain. Camouflaged materials may be provided inthe form of drapable sheets or net structures of varying shapes andsizes. Camouflaged materials in some instances may be a solid color. Inother applications, such materials may be dyed or printed in multiplepatterns to simulate the coloration or texture of the terrain in whichthe camouflage is utilized. Typical examples of colors that may beemployed include various patterns of black, brown, and green.

[0002] The disclosure of U.S. Pat. No. 5,486,385 describes a compositeproduct including an open mesh net substrate which is bonded to a sheetmaterial such as a woven fabric, non-woven fabric, knit fabric, or thelike. The sheet is colored in a desired camouflage pattern, bonded tothe substrate along spaced lines of attachment, and cut to simulate theappearance of natural objects of the terrain. Separate lobes are formedin the sheet to simulate the appearance of natural objects in theterrain, such as leaves or foliage. Then, the lobes are heated as muchas 400 degrees Fahrenheit to wrinkle and deluster the camouflage lobes.

[0003] To improve the camouflage characteristics of such composites, itis desirable to introduce three-dimensional effects to the materials.That is, wrinkling or gathering of the materials is desirable, andresults in a visual effect that more closely simulates natural terrain.Methods and products that result in a more highly wrinkled and a greaterthree-dimensional effect upon the structure are desirable.

[0004] Robinson Laboratories, Inc. of 110 North Park Drive, CannonFalls, Minn. 55009 distributes commercially a camouflaged productdesignated “3D REAL LEAF”™. This product is said to provide a layeredcomposition having a first backing layer and a second leafy layer thatis stitched to the backing layer. It is believed that a differentialfeed rate is employed in the construction of this product to provide abunching of material along stitched seams.

[0005] The durability and tightness of the stitching in camouflagecomposite constructions is an important factor in the overalleffectiveness of the camouflage composite. Camouflaged materialstypically are used outdoors in rugged environments. Therefore, aconstruction that is physically strong, durable, and provides maximumthree-dimensional effect is highly desirable. The durability of thethree-dimensional effect depends upon the stitch or thread maintainingits position relative to other layers of the construction. A stitchedseam of thread preferably should provide a high degree of structuralintegrity to maintain its physical form during use, thereby providingmaximum three-dimensional effects to the composite fabric construction.It is therefore desirable to provide a thread for stitching that willexhibit superior strength and resist elongation of the compositeconstruction along the seam. A thread for stitching that is adapted tomaintain or enhance three-dimensional gathering effects along a seamalso is desirable. A seam that will show a high degree of resistance tobreakage when opposed fabric layers are subjected to a separating forcealso would be desirable.

BRIEF DESCRIPTION OF THE DRAWINGS

[0006] A full and enabling disclosure of this invention, including thebest mode shown to one of ordinary skill in the art, is set forth inthis specification. The following Figures illustrate the invention:

[0007]FIG. 1 shows a plan view of a first embodiment of the compositeconstruction of the invention which employs a net mesh backing materialas a first textile substrate in the camouflage construction, theconstruction including spaced parallel seams running vertically in themachine direction of the construction;

[0008]FIG. 2 shows an end view of the camouflage construction seen inFIG. 1;

[0009]FIG. 3 depicts a second embodiment of the invention which employsa solid first textile substrate backing material, also containingvertically oriented parallel seams;

[0010]FIG. 4 shows an end view of the camouflage construction seen inFIG. 3;

[0011]FIG. 5 is a side elevation view depicting schematically some ofthe principal components of the apparatus for producing the camouflageconstruction of the invention;

[0012]FIG. 6 is an enlarged side sectional elevation view of the cuttinghead of the cutting station of the apparatus of FIG. 5;

[0013]FIG. 7 is a front elevation view of a portion of the cutting headstation of the apparatus of FIGS. 5 and 6, looking generally in thedirection of arrows 7-7 of FIG. 6; and

[0014]FIG. 8 is a top plan view of a portion of the cutting head of thecutting station of the apparatus of FIG. 5 taken generally along line8-8 of FIG. 6, and looking in the direction of the arrows;

[0015]FIG. 9 illustrates properties of one preferred thread that may beused in the present invention, in which shrinkage % versus draw ratio ofthis particular cold drawn thread is presented;

[0016]FIG. 10 shows breaking elongation of the thread presented in FIG.9;

[0017]FIG. 11 illustrates breaking strength of the thread previouslypresented in relation to FIGS. 10-11; and

[0018]FIG. 12 graphically depicts breaking tenacity versus draw ratiofor the same cold drawn thread of FIGS. 9-11.

DETAILED DESCRIPTION OF THE INVENTION

[0019] Reference now will be made to the embodiments of the invention,one or more examples of which are set forth below. Each example isprovided by way of explanation of the invention, not as a limitation ofthe invention. In fact, it will be apparent to those skilled in the artthat various modifications and variations can be made in this inventionwithout departing from the scope or spirit of the invention.

[0020] Surprisingly, it has been discovered that by modifying certaincommercially available yarn, a new high-shrink material may be formedwhich shrinks upon application of heat. This material may be used as ayarn, or as a thread. In the application of the invention, it has beenfound that use as a thread is very useful, to connect two or moretextile substrates, as further described herein. Such a thread may beemployed in a stitch to connect a number of textile substrates, therebyforming a connected composite textile construction. Upon the applicationof heat to the composite construction with shrinkable thread, ashrink-hardened seam may be formed along the stitch. Shinkage amounts ofsuch thread may be as much as 70% of the actual thread length, asfurther described below. The number of stitches per linear inch in thecomposite construction upon heating may increase as well (due to threadshrinkage, primarily), by as much as 10-20%.

[0021] Conventional textile and sewing applications employ a thread oryarn which exhibits very little shrinkage after it is applied in astitch. That is, shrinkage of thread typically is intentionally avoidedin the manufacture of textile articles.

[0022] However, in the application of the invention, a high degree ofshrinkage is desirable to form a shrink-hardened seam connecting atleast two textile substates. Upon forming a layered composite bystitching with the high-shrink thread, and subsequently heating thecomposite construction, the thread length decreases and thereforetightens against the joined substrate layers, which serves to maximizethe amount of bunching or gathering of such mated textile substrates.

[0023] A maximum amount of bunching or gathering increases the visualthree-dimensional effect of the fabric. Thus, high shrink thread may beemployed to achieve a shrink-hardened seam in camouflage fabrics tomaximize the visual performance of such fabrics.

[0024] For purposes of this specification, materials used for stitchingtwo separate pieces of textile to each other shall be referred to hereinas “thread” and not “yarn”. However, the invention may be applied in theuse of such high shrink materials in “yarn” applications as well as inthread applications. In general, for purposes of this description, ayarn is described as a textile useful for manufacture of a sheetedmaterial, while a thread is used as a connecting mechanism for one ormore sheeted materials. Furthermore, the use of the “textile” shall notbe limited to sheet or woven materials, and may include as well flexiblefilms, such as for example, urethane films and the like.

[0025] In one application of the invention, it is possible to provide amulti-layered camouflage construction having three-dimensional qualitieswith reduced luster and increased gathering or wrinkling. The camouflageconstruction may closely approximate the visual appearance of terrain.The construction may comprise two substrates mated to each other andstitched along their length using high-shrink thread. The threadsubsequently may be heated to bunch or gather the fabric along thestitched seam, thereby forming a shrink-hardened seam. Thus, a gatheredthree-dimensional appearance may be formed in either or both of thefirst or second substrate, depending upon the particular application,and the amount of gathering necessary in the particular composite beingmanufactured.

[0026] This bunching or gathering effect also may be achieved in twodirections which are perpendicular to each other (i.e. cross and machinedirection) upon the substrate, using techniques further described below.Furthermore, in the application of the invention it is not necessary ordesirable to use different running speeds of the first substraterelative to the second substrate to achieve gathering or bunching in thefinal composite construction.

[0027] A first textile substrate, also known as a “base” fabric, may bestitched to a second textile substrate. The second textile substrate maycomprise leaf-shaped nodes as further described below. The so-calledbase fabric may be heatset fabric, or non-heatset fabric, depending uponwhether or not it is desired to shrink the base fabric further usingheat once the composite is manufactured. That is, the base fabric itselfalso may be made to shrink, and this effect is especially pronounced inthe applications which use non-heatset base fabric. Shrinkage of threadalong a seam is desired, in many applications. Other applications of theinvention, however, may employ elastic or elastic-containing materialsto achieving bunching or gathering along a seam, including for examplematerials such as LYCRA™ (believed to be a trademark of the DuPontCompany of Wilmington, Del.).

[0028] The second textile substrate from which nodes or leaf-shapedmaterial is to be cut can be dyed, printed, or greige fabric. Alightweight 100% polyester woven fabric is believed to be veryadvantageous, but other fabrics and fibers may be employed as well,including poly/cotton blends, knits, non-wovens, and the like.

[0029] The thread employed to stitch together and form a shrink-hardenedseam connecting the above referenced two textile substrate layers may beselected from many different thread types. One particularly advantageousthread type is a high shrink solution dyed polyester thread.

[0030] In one preferred application, the thread is applied in a chainstitch at a rate of about 5 to about 20 stitches per inch, mostpreferably about 10 stitches per inch. The size or denier of the threadplays an important role in the practice of the invention. A greaterthread size used in a composite is believed to provide an enhancedgathering strength within the composite. Therefore, thread shrinking isdirectly related to the amount of bunching or gathering of material thatmay be achieved along a seam. Thus, thread size may affect the overallthree-dimensional textile appearance and performance of a camouflagecomposite construction.

[0031] Referring to the drawings, FIG. 1 shows a first embodiment of theinvention which comprises a multi-layered camouflage construction 21.The camouflage construction 21 is comprised of a first textile substrate22 and a second textile substrate 23 which overlays the first textilesubstrate 22. The first textile substrate 22 comprises a first end 30and a second opposite end 31. In this particular embodiment, the firsttextile substrate 22 is of an open mesh type, as seen in FIG. 1. Thesecond textile substrate 23 provides a plurality of transverselyorientated lobes 24 which are aligned along first line of attachment 25,second line of attachment 26, third line of attachment 27, and fourthline of attachment 28, as examples. FIG. 1 shows only a partial view ofthe entire fabric that could be manufactured, and the number of separatelines of attachment which could be used will vary depending on theparticular application. Each lobe 24 includes a base portion 33 which isconnected to a line of attachment 25, and an outer wrinkled in portion34 which is directed towards an opposite line of attachment. In thisway, the lobes are oriented towards each other, and in alternatingsequence, so they substantially cover, but do not completely cover, thefirst textile substrate 22.

[0032]FIG. 1 illustrates the bunching or gathering of the first textilesubstrate 22 and the second textile substrate 23 which may be effectedin several ways, at least one of which is described herein. The bunchingor gathering of the first textile substrate 22 provides advantageousthree-dimensional visual characteristics that contributes to theeffectiveness of the camouflage construction 21 in sumulating terrain.In the particular embodiment of FIG. 1, the bunching or gathering of thefirst textile substrate 22 is provided along the length of the firstthread 35 along the first line of attachment 25 into a shrink-hardenedseam 29 a, and by a second thread 36 along the second line of attachment26, which runs along shrink-hardened seam 29 b. Further, a third thread37 is provided along the third line attachment 27 to formshrink-hardened seam 29 c, and the fourth thread 38 along the fourthline of attachment 28 forms a shrink-hardened seam 29 d.

[0033]FIG. 2 illustrates an end view of the first embodiment of theinvention previously seen in FIG. 1. In FIG. 2, the multi-layeredcamouflage construction 21 is a multi-layered composite. The firsttextile substrate 22 is seen underneath, while the first thread 35,second thread 36, third thread 37, and fourth thread 38 are shown incross section at the point at which they attach the first textilesubstrate 22 to the second textile substrate 23. This attachment occursat the lines of attachment 25-28, respectively. Furthermore, the secondtextile substrate 23 is seen projecting upwards to provide athree-dimensional effect upon the overall camouflage construction 21.The shrink-hardened seams 29 a-d are seen in cross-section in the FIG.2.

[0034]FIG. 3 illustrates a second embodiment of the invention in which amulti-layered camouflage construction 50 is comprised of a first textilesubstrate 51 (with first end 62 and second end 63) that is solid in form(as opposed the mesh net configurations of FIG. 1-2), and a secondtextile substrate 52. In the particular example of FIG. 3, the firsttextile substrate comprises a solid poly-cotton material, but othersolid sheets of material can also be used, as further described herein.A plurality of lobes are provided, including for example lobe 54 havinga base portion 55 connected to third line of attachment 60, and a outerwrinkled end portion 56 which projects above the first textile substrate51.

[0035] From left to right as seen in FIG. 3, a first line of attachment58, a second line of attachment 59, a third line of attachment 60, and afourth line of attachment 61 extend parallel to each other from thefirst end 62 of the first textile substrate 51 to the second end 63 ofthe first textile substrate 51. Furthermore, the lines of attachment areformed by first thread 65 (which forms shrink-hardened seam 49 a),second thread 66 (which forms shrink-hardened seam 49 b), third thread67 (which forms shrink-hardened seam 49 c), and fourth thread 68 (whichforms shrink-hardened seam 49 d), respectively.

[0036]FIG. 4 illustrates an end view of the second embodiment of theinvention of FIG. 3, showing the above recited features in end view.

[0037]FIGS. 5-8 illustrate manufacturing procedures employed to producethe multi-layered composite construction of the invention. U.S. Pat.Nos. 5,486,385; 5, 281,451; 5,013,375; 5,476,561; and 4,931,320; eachrelate to constructions and methods of making various embodiments ofcamouflage construction materials. Reference is therefore made to thesegranted patents for general information regarding the manufacture ofsuch articles.

[0038] Delustering of camouflage net resulting in low degree ofreflection makes the composite camouflage construction difficult toobserve, and is therefore desirable. Furthermore, the melting andwrinkling of camouflage lobes results in greater air movement beingpossible through the net, with reference to the embodiment of FIGS. 1-2.This is particularly useful in applications of the construction as adrape or covering over large pieces of equipment, in which wind or airresistance may become a significant factor due to the large surface areaexposed to wind. In clothing applications, air movement may contributeto comfort for the wearer. One additional means of wrinkling anddelustering camouflage lobes is the application of heated pressurizedgas streams to the camouflage.

[0039] Method and apparatus for producing the lightweight camouflagefabric in accordance with the present invention may be described byreference to FIGS. 5-8. In FIGS. 5-8, the multi-layered camouflageconstruction of FIGS. 1-2 is shown, by way of example. As seen inschematic side elevation view in FIG. 5, an indefinite length continuoussheet of material, such as a second textile substrate 23, and anindefinite length web of the first textile substrate 22 (such as aknitted mesh fabric in this instance) are directed from supply rolls124, 126 respectively by suitable guide means, such as rollers or bars128. The substrates 22, 23 are provided in contiguous facing relationalong the desired path of travel, as shown by the arrows in FIG. 5.

[0040] Spaced in the path of travel are bonding means, such as a sewingstation 130 containing a plurality of individual sewing heads 131 spacedacross the cross direction of the process or pathway. The second textilesubstrate 23 is stitched to the first textile substrate 22 along first,second, third and fourth lines of attachment 25-28 (see FIGS. 1-2).

[0041] Typically, the sewing means used is a Malimo RTM stitch-bondingmachine, which is known in the industry. However, other machines couldbe employed, including for example straight-line quilting machines.Stitch-bonding of the sheet or second textile substrate 23 and firsttextile substrate 22 along plural lines of attachment during movement ofthe multi-layered camouflage construction 21 through the bonding meansproduces a plurality of continuous open-ended channels 132 a-f (FIG. 8)in the composite bonded structure. Any number of stitches per inch maybe employed, but it has been found that stitches applied at a rate ofbout 5-20 stitches per inch are advantageous. Furthermore the width ofsuch open-ended channels 132 a-f may be between about 1-10 inches,preferably about 2-3 inches. One very useful embodiment employs channels132 a-f having a width of about 3 and one-eighth inches.

[0042] Positioned in the path of travel of the composite bonded sheetand substrate after the sewing station 130 are multiple cutting means,located at a cutting station 134. As seen in FIGS. 5-8, cutting station134 includes a plurality of generally U-shaped guides 136 mounted inspaced relation across the path of travel of the textile substrates22,23 on cross member 137 of support frame 138. As the composite webmoves in its longitudinal path of travel (see direction arrows in FIGS.5 and 6), the guides 136 pass into each of the respective channels 132a-f (see FIG. 8) formed between adjacent lines of attachment 25-28 ofthe first and second textile substrates 22,23. Each U-shaped guide 136is of sufficient thickness and height (FIG. 6) to separate and space theface of the second textile substrate 23 at a distance from the face ofthe first textile substrate 22.

[0043] Cutting means are mounted for reciprocating movement andpositioned transverse to the path of travel of the substrates 22,23,shown as a plurality of electrically heated wires 140, each of which ismounted on cutters 142 of an insulator bar 144. Insulator bar 144 isattached by elevator mechanisms 145 a-c to cross beam 146 on the supportframe 38. The beam 146 is mounted on rods 147 for transversereciprocation on frame 138, across the path (in the cross direction) ofweb travel. Beam 146 is, therefore, reciprocated by suitable drivemeans, such as for example pneumatically controlled programmed pistonmotor 148 (see FIG. 7).

[0044] As best seen in FIGS. 6 and 7, each heated wire 140 extendsdownwardly to reside and reciprocate within the confines of eachU-shaped guide member 136, moving very quickly to provide a movementthat approximates the outline or exterior shape desired for constructionof each lobe 24. Electrical energy is supplied from a suitable supplysource to heat the wires 140 to a desired temperature to cut thecontinuous sheet fabric (or second textile substrate 23) withoutcontacting or adversely affecting the supporting first textile substrate22, which also is attached.

[0045] Cross beam 146 is reciprocated by a suitable drive means, such asmotor 148 that is coupled to a ball screw 165 by means of a coupler 173.The ball screw 165 is rotatably attached to support frame 138 by meansof a dual attachment members 167. The ball screw nut 174 is fixed tocross beam 46. As best seen in FIGS. 6 and 7, each electrically heatedair cutter 142 extends downwardly to reside and reciprocate slightlyabove each U-shaped guide member 136. Electrical energy is supplied froma suitable supply source to electrical wire 162 to heat the inside ofair cutter 142 to the desired temperature. In other applications (notshown in the Figures), a laser cutter could be employed. Furthermore,air is supplied from a suitable supply source to air conduit 163, whichinjects the air into the air cutter 142 to thereby cut by means of anair stream the continuous woven fabric 23 without cutting the supportingknitted mesh fabric 22, which is attached.

[0046] Operation of the motor 148 driving the ball screw 165 thusreciprocates the cross beam 146 holding each of the electrically heatedair cutters 142 to move transversely back and forth slightly above eachof their U-shaped guides 136 as the woven fabric 23 and knitted meshfabric 22 move through the cutting station 134. The electrically heatedair cutters 142 cut the woven fabric 23, between the adjacent lines ofattachment 25-28, into a plurality of lobes 24, thus opening each of thechannels 132 a-f formed in the woven fabric 23 and knitted mesh fabric22 as the multi-layered camouflage construction 21 passes throughcutting station 134.

[0047] The shape and configuration of lobes 24 prior to heating may bevaried, as desired, depending on the speed of movement through thecutting station 134 and the speed of reciprocation of the electricallyheated air cutters 142. The speed of movement of the electrically heatedair cutters 142 may be adjusted by adjustment of the servo motor speed.Various programming means well known in the art may be employed toprovide varying and various patterns of lobes 24, as desired. Operationof the cutting station may be computer-controlled, but this is notrequired. Other embodiments may employ other means for cutting lobes, inwhich there is no cross beam 146, but instead each U-shaped cuttingguide member 136 is configured for independent movement, therebyproviding an opportunity for randomly cut leaf patterns along thecomposite. However, it should be recognized that other embodiments notspecifically shown could employ techniques of cutting lobes orleaf-shaped portions in the second textile substrate prior to joiningthe second textile substrate to the first textile substrate, andtherefore the invention is not limited to only those cutting andassembly methods and apparatus shown herein.

[0048] As shown in one desirable embodiment, electrically heated aircutters 142 are operated to provide a lobe configuration resembling asimulated leaf shape. The camouflage construction 21 may be suitablydyed or printed in a desired camouflage configuration of randomcoloration. The woven fabric 20 and knitted mesh fabric 22 preferablyeach may be dyed or printed prior to bonding to each other, andsubsequent cutting.

[0049] Typically, the knitted mesh fabric 22 forming the net substratewhich supports the second (woven) textile substrate 23 in the form of acontinuous sheet may be dyed black, or a neutral background shade. Itmay be formed of essentially common textile material, including knit,polyester, or the like. The continuous sheet or second textile substrate23 may be patterned in random green, brown, black coloration to conformto terrain in which the camouflage construction is employed. Asmentioned, the particular mesh size of the net support substrate may bevaried, but preferably it is sufficiently small size as to not snag onobjects or equipment to be concealed. Similarly the distance between thelines of attachment of the sheet to the substrate may vary, dependingupon the length and the size of the lobe desired for simulation ofleaves or foliage, but about 2-6 inches has been found to work well,with about three and one-eighth inches being preferred.

[0050] The camouflage construction 21 leaving the cutting station 34(see FIG. 5) is passed through guide rolls 151 and 152 and is directeddownwardly to a creasing roll 154. This allows the lobes 24 to fallfreely away from the mesh backing prior to passage through the heater156.

[0051] Importantly, heater 156 applies energy to the underside of themulti-layered camouflage construction. The heater operates preferably inthe range of 200-400 degrees. Fahrenheit. In the heater 156 the lobestend to shrink while they curl away from the mesh 12, serving toincrease the three-dimensional effect.

[0052] One important function of heating the underside or backside 53 ofthe multi-layered construction is that the threads 35-38 forming thelines of attachment 25-29 shrink substantially, thereby forming what isreferred to herein as shrink-hardened seams 29 a-d. The threads areparticularly susceptible to infared radiation which is incident on theouter thread surface, as shown in FIG. 5. However, other heat sourceswhich are not infared also could be employed in the invention. It ispreferred that the processing speed be adjusted so that a particularthread portion may spend about 5 seconds at heater temperatures ofbetween 250-400 degrees F. to faciliate full shrinkage effects. Theexact temperature that is ideal in any given application will dependupon the materials used, the thread used, the denier of the thread,whether or not the thread is a multi-ply thread, and the like. Threadshrinkage amounts for one particularly useful thread is shown anddiscussed herein with respect to FIGS. 9-12, including both a technicaldescription and a summary of testing of such thread.

[0053] The fabric 50 passes around the creasing roll 54 (see FIG. 5)with the curved lobes facing the roll so that crease lines 58 are formedin the lobes to produce the fabric 21 shown in FIG. 1. As can be seen inFIG. 1 the crease lines 58 are random so that the exposed portions ofthe lobes 24 are random. Furthermore, heating of the threads 35, 36, 37,and 38 along respective lines of attachment 25-28 results in formationof shrink-hardened seams 29 a-d.

[0054] The multi-layered camouflage construction 21 may be suitable dyedor printed in a desired camouflage configuration of random coloration.The sheet or second textile substrate 23 and the first textile substrate22 may be dyed or printed prior to bonding and cutting. Typically, thenet substrate (first textile substrate 22) which supports the continuoussheet is dyed or printed black, partially black, while, tan, green, or aneutral background shade, depending upon is the terrain to be simulated.The second textile substrate 23 may be patterned in random green, brown,and black coloration to conform to terrain in which the camouflageconstruction is employed.

[0055] The particular mesh size of the first textile substrate or netsupport backing 22 may be varied, but preferably it is sufficientlysmall in mesh size as to not snag on objects or equipment which isintended to be concealed. Similarly, the distance between the stitchlines of attachment of the sheet to the substrate may vary, dependingupon the length and the size of the lobes desired for simulation ofleaves or foliage in the terrain to be simulated. The net supportbacking 22 may be comprised of many different type of materials,including polyester, nylon, polypropylene, films, polyester copolymers,olefins, polyethylene, and other polymeric materials.

[0056] A textile substrate may be provided in an overfeed condition dueto shinkage of the composite construction 21 in the machine direction asheating progresses. A feeding rate of about 6.9 yards per minute may beemployed after the stitching is accomplished, at the point in FIG. 5wherein the composite passes roll 151 and roll 152, and moves towardsthe above referenced heater 156. The web output beyond the heater (pastthe ironing roll 154) is typically at a rate of about 5.7 yards perminute.

[0057] Thus, the overall rate at which ironing roll 154 turns is about17.4% faster than the rotation of roll 152 to accommodate for shrinkagein the machine direction that is observed when employing a high shrinkthread as recited herein. This variation in web processing speed may bereferred to as an overfeed.

Cold Drawn Thread Preparation

[0058] In the application of the invention, thread employed in sewingstation 130 to produce camouflage construction 21 may be of manydifferent types, and is not limited to any particular thread citedherein. Furthermore, some applications of the invention may use a singleply yarn, while other applications may use a two, three, four or moreply yarn as a base or starting material for thread construction. Yarnmaterials manufactured and distributed by Kosa, DuPont, Nanya (divisionof Formosa Plastics in Taiwan) and others could be employed in thepractice of the invention. However, one particularly useful yarn whichmay be used in this application is purchased and then processed asfurther described below, prior to use. Materials including nylon,polyester, polypropylene, and others may be employed to construct a highstrength thread capable of shrinking upon addition of heat, forapplication in the invention.

[0059] Two plies of Omara partially oriented polyester yarn (270 denier;34 filament) may be employed and then modified in the practice of theinvention. The Omara yarn employed for the particular examples asdiscussed herein is a solution dyed partially oriented (POY) polyestermaterial, and it may be purchased from the manufacturer OmaraCorporation.

[0060] The yarn, after purchase, is modified by cold drawning at ambienttemperature at a speed of about 400 meters/minute. Two plies of about150 denier are intertangled to provide a thread for stitching. Thethread is applied in sewing station 130. The stitch applied may beregular, irregular, continuous, or discontinuous. In some applicationsof the invention, no twist is provided in the thread, while in otherapplications twist is applied. In a preferred embodiment of theinvention, a twist of less than about 1 turn per inch is applied,however, the invention is not limited to any particular amount of twist,or the presence of absence of twist in the thread. The thread then iscapable of substantial shrinkage when subsequently exposed to heat, dueto having been drawn cold. The substantial shrinkage upon application ofheat generates the hardened seam of the invention, which has shown to beparticularly useful in this application.

[0061] The hardened seams which result from the use of such cold drawnthread in the application of the composite construction is referred toherein as a “shrink-hardened” or “shrunk-hardened” seam, regardless ofthe specific type, size, or manufacturer that supplies the specificthread that is employed to manufacture such a hardened seam. In general,for purposes of this description, a “shrink-hardened seam” or “hardenedseam” shall refer to any seam of thread in which the seam is stitched toconnect two or more substrates, and then the thread is heated orotherwise energized to shrink the thread in place upon the substrates,resulting in a thread that is in tensioning relation to a substrate.Further, such a hardened seam causes the substate or fabric to which itis attached to become gathered or bunched along the seam. Ashrink-hardened seam has been found to be particularly hardened anddurable in such camouflage constructions, such a strong seam beingconfigured for long life and low maintenance.

Testing of Cold Drawn Thread

[0062] Various testing was conducted for samples of cold drawn Omarathread as above described. FIG. 9 shows a shrinkage test to determinetotal shrinkage of the Omara cold drawn thread, and was accomplishedaccording to ASTM 4031.

[0063] In general, the results of shrinkage testing of the Omara colddrawn thread indicate that thread run with a draw ratio of between about1.3 and 1.6 exhibits the greatest degree of shrinkage (as much as 70% asshown in FIG. 9) and is thus the most desirable thread for thisparticular high-shrink application. Thus, a hardened seam may beproduced with a maximum amount of bunching or gathering by use of suchthread having such a draw ratio, for maximum three-dimensional effect.

[0064] Breaking elongation percentage results are reported in FIG. 10.Breaking strength results are reported in FIG. 11, and breaking tenacityis shown in FIG. 12.

[0065] Thread having an overall draw ratio of about 1.6 was employed inthe construction which is shown in FIGS. 1-2, FIGS. 3-4, and in theSamples A, B, and C below, as further described.

Samples

[0066] Product Samples were prepared for testing on the followingmulti-layered composite textile constructions. Each of the embodimentsshown below as Sample A, B, and C differ from each other only withregard to the first textile substrate, or “backing” layer that isemployed with each, as described.

Product Sample “A” Heat Set Mesh Construction

[0067] A multi-layered manufactured composite camouflage constructionwas prepared as described above in connection with the invention, andshown as well in FIGS. 1-2. This product includes a first textilesubstrate (backing layer) of non-heat set printed Rachel knit which maybe obtained from Royal Carolina.

[0068] The thread used along the multiple lines of attachment, orstitches, consisted of two-ply, high shrink Omara brand yarn which hadbeen modified as described above. Thread having an overall draw ratio ofabout 1.6 was used.

[0069] The thread was applied as {fraction (2/150)} denier that wasinserted using two ends per needle, at a rate of about 10 stitches perinch.

[0070] The thread was inserted by stitching as described above inconnection with FIGS. 5-9, and then shrink-hardened by heating as setforth above. The heater temperature at the heater was about 1100 degreesF., which resulted in a temperature on the fabric (and on the thread) ofabout 300-400 degrees F. After heating, the stitch count increased toabout 11 stitches per seam inch, due to thread shrinkage, and hardeningof the seam.

[0071] A single ply of the thread, when removed from the shrink-hardenedseam of the multi-layered construction was found to be about 418 denier.

Product Sample “B”—Non-Heat Set Mesh Construction

[0072] A multi-layered manufactured composite camouflage construction asdescribed above in connection with the invention. This product includesa first textile substrate (backing layer) of non-heat set printed Rachelknit (“Royal Carolina”). The fabric is printed and then heat set at 65inches width prior to mating with a second textile substrate.

[0073] Thread was used along the multiple lines of attachment, orstitches. The thread was two-ply Omara brand yarn which had been colddrawn modified as described above. Thread having a draw ratio of about1.6 was applied at 10 stitches per inch. The thread was applied as{fraction (2/150)} denier that was inserted using two ends per needle.

[0074] Upon heating to the same temperatures as described above inconnection with Sample A, the thread formed a shrink-hardened seamhaving about 11 stitches per linear inch of seam.

[0075] A single ply thread, when removed from the multi-layeredconstruction after final heating, was found to be about 421 denier.

Product Sample “C”—Integral or Solid Base Fabric Construction

[0076] A multi-layered manufactured composite camouflage construction asdescribed above in connection with the invention, and shown as well inconnection with FIGS. 3-4 was constructed. The first textile substrate,or “base” fabric that is employed is a solid (not mesh) dyedpolyester/cotton woven fabric.

[0077] The thread was used along the multiple lines of attachment, orstitches. The thread was Omara brand yarn described above. Heating wasas previously described in connection with Samples A and B. The threadwas applied as {fraction (2/150)} denier and inserted using two ends perneedle, resulting in 11 stitches per inch in the final product. A singleply of the thread, when removed from the multi-layered constructionafter final heating, was found to be about 417 denier.

Sample “D”—Commercial Product Manufactured by Robinson Laboratories

[0078] Robinson Laboratories, Inc. of 110 North Park Drive, CannonFalls, Minn. 55009 distributes commercially a camouflaged clothingproduct designated “3D REAL LEAF”™. A men's large (L) garment wastested.

Testing Procedure

[0079] Tensile Test (Grab): In executing the tensile test of specimensA, B, C and D, specimens were cut from the multi-layered camouflageconstruction into test strips along the stitched seam (in the machinedirection). The seam was in the center of each cut specimen, and thespecimen size was about 8 inches long (along the seam) in the machinedirection, and 3 inches wide in the cross direction. Specimens weregripped by opposing clamps, and force was applied along the longitudinallength of the seam until breakage of the specimens. The test determinedthe force required to break the seam in the machine direction, and thusmeasures the relative strength of the construction along the stitchedseam. Results are reported in Table 1.

[0080] Tensile Test of Thread: Tensile testing was conducted on threadremoved from the stitches of manufactured samples A, B, C, and D. Thethread was therefore de-stitched from the manufactured products, andthen placed in the test apparatus to determine the force required tobreak the thread alone. Results are shown in Table 2.

[0081] Seam Failure: This test determines the maximum sewn seam strengthwhich can be achieved when a force is applied perpendicular to the seam.Seam breakage at the stitch line is measured by taking each of theproduct samples A, B, C, and D and securing the outer leafy lobe (secondtextile substrate) to one test fixture, and the base fabric (firsttextile substrate) to a second test fixture. Then, force is applied inthe cross-direction (perpendicular to the seam) by the fixtures untilfailure of the seam. Results are shown in Table 3. TABLE 1 Tensile Test(Grab) of Sample Portions of Camouflage Construction Along Stitched SeamForce Required to Break- Percent Percent Peak Load Elongation atElongation at 10 Sample Mean (lbf) Peak Load (%) Lbs (%) A 110.31244.736 14.286 B 90.960 46.737 14.410 C 84.342 25.016 6.890 D 92.03771.252 23.517

[0082] TABLE 2 Tensile Results of Thread Portions From ManufacturedCamouflage Construction Force Required Percent to Break- Elongation atPeak Load Peak Load Sample lbf (Mean) (%) (Mean) A 1.705 34.897 B 1.49033.209 C 1.537 33.888 D 1.947 15.676

[0083] TABLE 3 Seam Failure of Manufactured Camouflage Construction byForcible Separation of Two Textile Substrate Layers at the Seam ForceRequired to Break Percent Peak Load Elongation at Sample lbf (Mean) PeakLoad (%) A 48.979 43.675 B 65.485 54.867 C 46.464 30.618 D 21.827 33.414

Brief Summary of Test Results

[0084] The tensile test results indicate that the various multi-layeredcamouflage constructions of the invention exhibit surprisingly goodresults for resisting elongation along the seam. In Table 1, it may benoted that all three examples of the invention (samples A, B, and C)resisted elongation along the seam significantly better than the sampleD product.

[0085] Testing of the integrity of the seam (Table 3) indicated that thethree embodiments of the invention exhibit surprisingly good results forseam integrity and strength. That is, the respective seams of samples A,B, and C resisted breakage substantially better than the seam of priorart sample D. All of the samples of the invention showed seam integrityup to at least 46 lbs of force. In fact, Sample B showed seam integrityup to a 65 lbs of force. The prior art sample D, however, failed at arelatively low force reading of only about 21 lbs of force.

[0086] It is understood by one of ordinary skill in the art that thepresent discussion is a description of exemplary embodiments only, andis not intended as limiting the broader aspects of the presentinvention, which broader aspects are embodied in the exemplaryconstructions. The invention is shown by example in the appended claims.

1-40. (Cancelled)
 41. A method of making a composite camouflagematerial, the method comprising the steps of: (a) providing a firsttextile substrate having a first end and a second end, said firsttextile substrate having a machine direction extending from said firstend to said second end, said first textile substrate further having across direction extending perpendicular to said machine direction, (b)providing a second textile substrate in facing relation to said firsttextile substrate, (c) providing a first thread portion, (d) connectingwith said first thread portion said first textile substrate to saidsecond textile substrate along a line of attachment, said line ofattachment extending in the machine direction, and (e) shrinking saidfirst thread portion to form a hardened seam along said line ofattachment, thereby gathering one of said first or second textilesubstrates along said line of attachment.
 42. The method of claim 41wherein the shrinking step is affected by applying heat to said firstthread portion.
 43. the method of claim 42 wherein said heat is appliedin the form of infrared radiation.
 44. The method of claim 43 whereinsaid heat is applied in a temperature range of between about 200 andabout 400 degrees Fahrenheit.
 45. The method of claim 41 wherein saidmethod further comprises, after said connecting step, the steps of:cutting said second textile substrate to form leaf-shaped lobes in saidsecond textile substrate.
 46. The method of claim 41 wherein said methodcomprises, prior to said connecting step, the step of: cutting saidsecond textile substrate to form leaf-shaped lobes in said secondtextile substrate.
 47. The method of claim 41 additionally comprisingthe step of: (f) shrinking said first textile substrate in the crossdirection, thereby gathering one of said first or second substrates inthe cross direction, thereby increasing the three-dimensional appearanceof said composite camouflage material.
 48. A method of making acomposite camouflage material, the method comprising the steps of: (a)providing a first textile substrate having a first end and a second end,said first textile substrate having a machine direction extending fromsaid first end to said second end, said first textile substrate furtherhaving a cross direction extending perpendicular to said machinedirection, (b) providing a second textile substrate in facing relationto said first textile substrate, (c) providing a plurality of threadportions, (d) sewing each of said plurality of thread portions upon saidfirst and second substrates, thereby connecting with said threadportions said first textile substrate to said second textile substratealong multiple lines of attachment, said multiple lines of attachmentextending in the machine direction along said first textile substrate,(e) heating said thread portions, and (f) shrinking said thread portionsto form a plurality of hardened seams along said multiple lines ofattachment, thereby gathering said second textile substrate along saidmultiple lines of attachment to form a three-dimensional effect uponsaid composite camouflage material.
 49. The method of claim 49 whereinprior to step (c) said thread portions are cold drawn, thereby providingthread portions with the capacity to shrink upon heating to form ahardened seam.
 50. A process of making a multi-layer compositeconstruction having three dimensional camouflage effects upon its outersurface, comprising the steps of: (a) providing a thread portion, (b)cold drawing said thread portion, (c) providing first and second textilesubstrates in facing relation to each other, (d) sewing said first andsecond textile substrates with said thread portion to form a multi-layercomposite construction, wherein said thread is provided in at least onestitch along said first and second substrates, (e) heating said threadportion, (f) shrinking said thread portion, and (g) thereby forming ahardened seam along said thread portion, said hardened seam beingcharacterized by gathered portions of one or both of said first andsecond textile portions along said hardened seam, said gathered portionsproviding three-dimensional effects upon said multi-layer compositeconstruction